Method for improved reinforcement baffling and sealing

Abstract

A method for reinforcing, baffling or sealing a vehicle structure, comprising the steps of providing one or more materials having a horizontal axis, at least one terminating edge, and an initial length, forming openings in the one or more materials, and applying the one or more materials to a location requiring reinforcement, baffling, sealing or any combination thereof.

We claim: 
     
       1. A method for reinforcing, baffling, or sealing a vehicle structure comprising:
 providing a carrier configured to be located on the vehicle structure; 
 extruding at least one expandable elements onto the carrier; 
 locating the carrier flush onto the vehicle structure; 
 wherein the at least one expandable element is configured to form an expanded element after expansion, the expanded element extending along the carrier, and wherein the at least one expandable element includes one or more openings. 
 
     
     
       2. The method of  claim 1 , wherein the at least one expandable element includes an expandable material that is formed of a heat activated material having foamable characteristics. 
     
     
       3. The method of  claim 1 , wherein the at least one expandable element includes a rigid polymeric material. 
     
     
       4. The method of  claim 1 , wherein the at least one expandable element includes an adhesive material. 
     
     
       5. The method of  claim 1 , wherein the at least one expandable element is substantially identical in shape and size. 
     
     
       6. The method of  claim 1 , wherein the at least one expandable element comprises one of a baffle material and a structural reinforcing material. 
     
     
       7. The method of  claim 1 , wherein the at least one expandable element includes one or more expandable elements formed of a material that differs from the other of the at least one expandable element. 
     
     
       8. The method of  claim 1 , wherein the one or more openings are alternating slits severing the at least one expandable element from both terminating edges while the at least one expandable element remains connected at a horizontal axis between the alternating slits; and
 wherein the one or more openings allow the at least one expandable element to be stretched to at least 1.2 times an original length of the at least one expandable element. 
 
     
     
       9. The method of  claim 1 , wherein a film layer is located on the carrier on a first side of the carrier which opposes a second side of the carrier; and
 wherein the at least one expandable element is secured to the second side. 
 
     
     
       10. The method of  claim 1 , wherein the expanded element expands to a height that is consistent along a length of the expanded element. 
     
     
       11. A method for reinforcing, baffling, or sealing a vehicle structure comprising:
 providing a carrier configured to be located on the vehicle structure; 
 extruding a plurality of expandable elements onto the carrier, each of the plurality of expandable elements formed of an expandable material; 
 locating the carrier flush onto the vehicle structure; 
 wherein the plurality of discrete expandable elements are configured to form an expanded element after expansion, the expanded element extending along the carrier, and wherein the plurality of expandable elements includes one or more openings formed in the plurality of expandable elements. 
 
     
     
       12. The method of  claim 11 , wherein the plurality of expandable elements comprise a material that is a heat activated material having foamable characteristics. 
     
     
       13. The method of  claim 11 , wherein the plurality of expandable elements comprise a rigid polymeric material. 
     
     
       14. The method of  claim 11 , wherein the plurality of expandable elements comprise an adhesive material. 
     
     
       15. The method of  claim 11 , wherein the plurality of expandable elements comprise one of a baffle material and one of a structural reinforcing material. 
     
     
       16. The method of  claim 11 , wherein the plurality of expandable elements are substantially identical to one another in shape and size.